Assignment on Additives in the Manufacture of Bricks and Special Types of Bricks
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1. Additives in the Manufacture of Bricks
During the manufacturing of bricks, raw clay is the main ingredient, but certain additives are
mixed with it to improve properties such as strength, workability, appearance, and resistance
to defects like cracking and efflorescence. The important additives are as follows:
(a) Sand
Added to clay to reduce shrinkage and warping during drying and burning.
Helps in preventing cracks.
Provides uniform shape and structure.
(b) Lime
Small quantities of finely powdered lime are added.
Lime reacts with silica in clay during burning to form calcium silicate, which imparts strength.
Improves the workability of clay.
Excess lime is harmful as it causes lime blowing (white patches).
(c) Iron Oxide
Added in small amounts to improve color and strength.
Gives a reddish or brownish tint to the brick during burning.
Helps in fusion of particles and enhances compressive strength.
Excess iron oxide makes bricks dark blue or blackish.
(d) Magnesia
Added to impart a yellowish tint and reduce shrinkage.
Provides uniform burning and prevents cracking.
(e) Alkalies
Act as a flux, reducing the melting temperature of silica and forming a glassy surface.
Improve vitrification and strength.
However, excess alkali causes efflorescence (white salt deposits).
(f) Organic Matter (e.g., Rice Husk, Sawdust, Straw, Coal Dust)
Added to make bricks porous and lightweight.
During burning, organic matter burns out, leaving small pores, thus reducing the weight of
the brick.
Useful for making insulating and light-weight bricks.
(g) Bauxite and Alumina
Used in special refractory bricks.
Improve heat resistance and fireproof qualities.
Summary:
Additives play a vital role in improving strength, appearance, workability, color, porosity, and
durability of bricks. The right proportion of additives ensures that the final bricks meet
construction standards.
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2. Bricks for Special Use
Apart from common burnt clay bricks, several special types of bricks are manufactured for
specific purposes:
(a) Engineering Bricks
Strong, dense, and durable.
Very low water absorption (<4%).
Used in bridges, sewers, manholes, and heavy engineering works.
(b) Facing Bricks
Manufactured for aesthetic appearance.
Smooth surface, uniform color, and attractive finish.
Used in outer walls, facades, and decorative works.
(c) Perforated Bricks
Contain cylindrical holes (10–20% of volume).
Lightweight and require less clay.
Provide better thermal insulation.
Used in partition walls and paneling.
(d) Hollow Bricks
Have larger cavities inside compared to perforated bricks.
Light in weight, provide sound and heat insulation.
Used in multistorey buildings and partitions.
(e) Fire Bricks (Refractory Bricks)
Manufactured from refractory clay (alumina content 20–40%).
Withstand very high temperatures (up to 1600°C).
Used in furnaces, kilns, fireplaces, and chimneys.
(f) Acid Resistant Bricks
Made from silica and shale with very low lime.
Highly resistant to acids, alkalis, and corrosive chemicals.
Used in chemical plants, fertilizer factories, and battery rooms.
(g) Paving Bricks
Dense, hard, and durable.
Able to resist wear, load, and impact.
Used for road pavements, floors, and paths.
(h) Glazed Bricks
Surface coated with colored glaze and fired again at high temperature.
Smooth, shiny, and decorative.
Used in facing works, kitchens, bathrooms, and decorative walls.
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3. Refractory Bricks (Fire Bricks)
Refractory bricks, also known as fire bricks, are a special category of bricks designed to
withstand high temperatures without melting or deforming.
Properties
High alumina content (20–40%).
Can resist temperatures up to 1600°C or more.
High compressive strength and durability.
Resistant to sudden changes in temperature (thermal shock).
Porous structure allows them to withstand expansion and contraction.
Types of Refractory Bricks
1. Silica Bricks – High silica content, withstand up to 2000°C, used in coke ovens.
2. Magnesia Bricks – Made of magnesite, resist basic slags, used in steel furnaces.
3. Fireclay Bricks – Most common refractory bricks, used in domestic fireplaces and
industrial furnaces.
4. High Alumina Bricks – Stronger and more durable, used in blast furnaces and cement
kilns.
Uses
Metallurgical Industries (steel and iron furnaces).
Cement and Glass Industries.
Power Plants (boilers and chimneys).
Household Uses (fireplaces, ovens, stoves).
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Conclusion
Additives improve the quality of bricks by enhancing strength, durability, and appearance.
For special construction needs, different types of bricks are manufactured such as
engineering, facing, hollow, perforated, and refractory bricks. Among them, fire bricks
(refractory bricks) are extremely important in industries where resistance to high temperature
and chemical attack is required.
Thus, understanding the use of additives and special types of bricks helps in selecting the
right brick for the right purpose, ensuring economy, durability, and safety in construction.